Automatic pump controller



March 3, 1942. M. A. OTTERBOURG AUTOMATIC PUMP CONTROLLER Filed Feb. 18, 1941 2 SheetsSheet l 2w g E vs 17.1% ON. om.

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, Q n o JIL mm v Nm 1 we 3nventot; M HRION H. Omeraaowaa C(ttorneg 5 Patented Mar. 3, 1942 UNITED STATES PATENT OFFICE AUTOMATIC PUMP CONTROLLER Marion A. Otterbourg, Charlotte, N. 0. Application February 13, 1941, Serial No. 379,404

8 Claims.

This invention relates to an apparatus for automatically maintaining a supply of water in tanks, reservoirs and the like and forms a continuation in part of my co-pending application, Serial Number 330,550 filed April 19, 1940.

More particularly, it is designed for the operation of water towers and tanks in which the water level constantly changes and in which the tank is removed a considerable distance from the source of supply. For example, it frequently occurs in supply tanks for railroad engines that it is necessary to locate the water supply tank several miles from the pumping station. In order to maintain an available supply of water, within the tank between predetermined levels, some direct connection is usually made between the tank and the pumping station whereby the pump will .be started or stopped as the occasion may require.

Heretofore, various mechanisms have been employed, the most commonly used being that of a mechanical float in the tank which operates a suitable switch to start the motor to the pump when the low level was reached and which likewise cuts off the switch when the high level was reached. This made it necessary to provide a control line between the pumping station and the water supply tank which adds greatly to the cost. In addition, the mechanical float frequently becomes frozen or out of order especially in cold weather, thereby rendering the starting and stopping means ineffective.

In other forms, the mechanical float as well as the lines have been eliminated and special presure operated switches have been employed for starting and stopping the pump, vAs has been stated, the pump is frequently located several miles from the tank and therefore a considerable friction head is incurred by pumping the water from between these two points; consequently, it has been impractical to stop the motor by virtue of the pressure within the tank because the friction in the pipe and the variable diflerences in the levels of water will cause the head to vary to such an extent that the stopping will not be within the required limit. When the pressure method is used for stopping the motor, it has frequently occurred that the tank will overflow before the pressure is registered on the gauge at the pump house.

It is therefore an object of this invention to provide means for starting and stopping a pump for maintaining a head of water between two levels in the tank, comprising means operated by the static head of said tank for starting the pump and means operated by a time motor for stopping the pump after said motor has been allowed to run for a predetermined interval. It is evident that when the water in the tank reaches its low level there is no flow in thepipe which connects the tank to the pump; consequently, the static head remains constant. On the other hand, after the pump has been allowed to run in order to pump additional water into the tank, the head of water cannot be accurately determined as the water is constantly flowing within the pipe. This difficulty is produced by the fact that the pipe line cannot be perfectly constructed so that there will be no air pockets or friction therein. These elements contribute to a varying pressure on the gauge at the pump-- ing end of the line. Also where there is a centrifugal pump employed for lifting the water from a reservoir into the tank, the difference in the elevation of the water level in the reservoir will also cause the registered apparent head to change due to the load which is placed on the centrifugal pump. By providing a means operated by the static head for starting the pump when the motor reaches its low level and using a suitable clock motor or time device, for stopping the pump after it has pumped a predetermined interval, it is evident that the water may be accurately maintained between two levels since the starting point can be accurately determined from the static head, and the stopping point can be accurately determined from the timed motor.

It is another object of this invention to provide an apparatus of the class described in combination with a safety appliance for the protection of the motor and pump. If for any reason, the pump should fail to pick up water after a predetermined number of attempts, the safety appliance will cut off the pump motor. pump will remain cut on until the switch is manually reset and of course before it is reset the operator will have an opportunity to remedy the existing trouble. Such a safety appliance will prevent damage to the motor and the pump which results from the failure of the pump to pick up water from the reservoir and force it to a suitable stand pipe.

Another very important result is obtained by using the above-named safety feature, namely, the prevention of a complete water failure in the tank or standpipe as a result of the pump continuously operating on air. Ordinarily the water would be drawn from the tank in the usual amounts while the pump continues to operate without lifting any water into the tank and as a result, there would, of course, eventually be a complete failure of water supply. However, with the use of the invention, when the failure of the pump to lift water is due to accumulation of air, the periodic stop and start feature of the device will usually act to cause the pump to take hold and deliver water during one of the successive automatic starting and stopping operations, thereby preventing a water failure. Also there This 1 is a pilot light which indicates imminent water failure.

Some of the objects of the invention having been stated, other objects will appear as the description proceeds, when taken in connection with the accompanying drawings, in which- Figure 1 shows a combined structural and diagrammatic view of the invention;

Figure 2 is a wiring diagram of the circuits for controlling the pump motor switch.

Referring more specifically to the drawings, the numeral l3 denotes a suitable source of water supply such as a lake or small pond in a stream, which supplies water to a reservoir II by means of a pipe i2. An intake pipe 13 has the lower end thereof disposed within this reservoir and has its upper end secured to the intake end of a suitable pump, which in the present instance is a centrifugal pump l hsaid pump being driven by an electric motor I5.

An outlet pipe l6 having a check valve I60. therein, leads from pump it to a stand-pipe or water tank l1 which may be disposed several miles distant. A by-pass pipe l3 leads around.

the check valve, said by-pass having a hand valve l9 therein which is used while priming the pump. In the construction of pipe line l6, it is necessary to substantially follow the contour of the earths surface thereby causing many irregularities and bends in the pipe line. These bends and irregularities tend to add to the friction of the flow as well as to form air pockets therein. All of these features change from day to day thereby causing the pressure at the outlet of the centrif- V ugal pump M to vary. It is, therefore, seen that it is impossible to accurately determine the head of the water which might be in the tank I! by measuring the pressure at the outlet of the pump M while the water is flowing in the pipe from the pump to the tank. Therefore, in order to stop the motor l5 after it has pumped the water to a predetermined level within the tank I1, it is necessary to start this motor by virtue of the static head after it has been lowered to a predetermined level and then provide means for causing the pump to runfor a predetermined time interval and then be. automatically cut off. Since the low level .can be accurately determined by the static head and the amount of water which pump M will pump within a predetermined time interval can be accurately determined, the high and low water heads within tank H can be accurately maintained in this manner.

The motor I5 has suitable leads Ll, L2 and,

L3, which supply the electric cur-rent. These leads have a conventional three blade switch placed therein, said blades being pivoted as at 2i, 22 and 23 and having the free ends adapted to contact terminals 2 5, 25, and 26 respectively. Switch 20 is moved to closed position by a suitable magnet Zl and is held in open position by a suitable spring 25.

The leads Li L2 and L3 also have a three blade service switch 29 therein which is manually closed and opened. Suitable fuses 33, 3| and 32 are placed in the leads Ll, L2 and L3, respectively. At points in lines Li, L2 and L3 between the fuses and the three blade switch 29, suitable conductors 33, 33 and 35 lead to another three blade switch 33. I

From the switch 35, wires 5t, 83 and 95 and i563 lead to a suitable control unit 31 and each of the wires has. a fuse 38 therein at 'a point near the switch 33. It will be noted by referring to Figure 1 that wire H0 leads from terminal 25 through the magnet 27 and then another wire I08 leads from the other Side of the magnet 27 into the control unit 31. Also a wire H5 leads from the point 22 on line L2 into a control unit 31. The function of the wires 5!, 88, 96 and I50, as well as wires I08, Ill H5, will be later described in connection with their respective circuits.

A pipe 39 leads from the pipe it at a point near the outlet side of the pump I l. The other end of pipe 39 has an enlarged portion MI in which is mounted a piston M. The upper end of which has a pin 42 contacting a lever 43. This lever is pivoted as at 44 and has an upstanding arm from which pin 45 extends laterally into a suitable slot 45, of a mercury tube 41. This tube is pivoted as at 48 and has a suitable supply of mercury 49 therein. A spring 50 normally tends to tilt the mercury tube to the bold line position as shown in Figure 2.

The piston 4| is normally forced downwardly by the spring 56 and is adapted to be forced upwardly by virtue of the pressure in the pipes 15 and 39, due to the starting of the pump it. Upon the starting of the pump, and upon Water being forced into the pipe I6 under pressure, the corresponding pressure will be transmitted through pipe 39 to the lower side of the piston ll in Figure 2. This will force the piston upwardly, rotate lever 43 in a counter-clockwise manner about pivot point 64 thereby rotating the mercury tube 41 about its pivot point 48 in a clockwise direction from the bold line position to dotted line position.

Control circuit for thermal switch When the apparatus is in position for operation, the switches 29 and 36 (Figure. 1) are closed, thereby establishing a connection between the leads Ll, L2 and L3, and the control unit 3?.

When the static pressure in pipe lines it and- 39 reaches a predetermined low, the mercury tube 41 will be tilted from dotted line position to bold line position as previously described. -This will close the circuit between wires 5% and 67 thereby allowing the current to flow from lead L3 through wire 35, switch 36, fuse 38, wire 5| metallic leaf 52 (Figure 2), contact 53, contact 54, wire 65, wire 66, mercury 49, wire 67, wire 63, post 65 of switch Til, wire "H, rheostat arm 72, rheostat l3, heater coil 80, wire 35, wire 33, back through fuse 38 (Figure 1), switch 36, wire 33, and back to lead LI thus completing the circuit. The heater coil is adapted to encircle a metallic strip 8| which is disposed around supporting arm 82 of switch in. The combination of members BI and 82 is called a bi-metallic strip, having two strips of metal with diiferent coefficients of expansion, and when suificiently heated the members 8| and 82 are deflected from bold line position to dotted line position. Of course when the arm 82 is deflected, the mercury tube 83 will likewise be deflected, thus causing the mercury 84 to flow to the other end of the tube and close the contact between wires NH and I02. The thermal switch assembly may be adjusted by manipulating the screw it and rheostat arm 72 so as to regulate the timing of the tilt necessary to cause the mercury to flow from one end of the tube to the other. For example, if it is desired to cause the mercury tube to tilt within one and one-half minutes, a different initial angularity would be set than would be the case if a shorter time interval were desired. In the present set-up, let us assume that the mer- 2,275,060 cury tube is set so that it would require about Magnetic motor switch circuit Upon the closing of the circuit between wires IM and I02, the current is allowed to flow from lead L2 to wire 34, switch 35, fuse 38, wire 95, three way manually controlled switch 96, wire I00, wire IOI, mercury tube 84, wire I02, wire I03, switch arm I04, contact I06, wire I01, wire I08 (Figure 2), magnet 21, wire I I and terminal 25 of lead L3, thereby energizing the magnet 21 and causing the blades of switch 20 to contact terminals 24, 25, 25 disposed in the circuit leading to the motor I and starting the pump I4 in operation. The friction head created by the pump action will immediately restore the pressure switch, which is designated by reference characters 39 to 50 inclusive, to dotted line open position, thus ole-energizing the thermal switch 10 in a set time causing the bi-metallic strip to assume its normal position, which of course, will cause the mercury tube 83 to be restored to bold line position at which time the circuit is broken between wires IM and I02. It will take approximately a minute to a minute and a half When the magnetic switch is closed by the above-named circuit, for starting the motor I5, the current is simultaneously taken from the terminal 22 of lead L2. The current flows through wire II5, switch arm 5, contact II8,

wire II9, contact I20 of time switch I2I, contact I22, metallic leaf I23, wire I24 and back to the Wire I01, thus completing the holding circuit. The motor I5 will now run until the time interval switch I2I has completed a cycle which will cause the contacts I20 and I22 to separate which, in turn, will cause the magnet 21 to be deenergized to stop the motor.

Time interval switch and circuit In Figure 2 it will be seen that the metallic:

leaf I23 has a roller I associated therewith. This roller is adapted to press against the periphery of cam I3I by virtue of the inherent resiliency in the metallic leaf. It is seen that the cam I3! has a low side I Me which, when contacted by roller I30 will allow the contact I22 to move into engagement with contact I20. In other words, the time that it is desired for the motor I5 and pump I4 to operate and pump water from the reservoir II to the tank I1 will be determined by the length of the low side I3Ia. Therefore, the shape of the cam I3I will largely be determined by the capacity of the tank and the amount of water desired to be pumped during any one time interval. I

The cam I3I is mounted upon a suitable shaft I32, the other end of which leads into a suitable gear reduction housing I33. Leading from the housing I 33 is a motor shaft I34 of motor I35. The circuit for operating this motor comprises a wire I40 which leads from. one side of the motor to the wire I24. Another wire I4I leads from the other side of the motor to wire I5, thereby supplying current to motor I35 when the motor I5 and the pump I4 is in operation, and of course depriving the motor I35 of current when the pump I4 and the motor I5 are not in operation.

Circuit for thermal switch 155 Now repeating the starting operation just described, assume that the pump I4 did not pick up water and therefore no friction head was created to restore the pressure switch comprising parts 39 to 50 inclusive to open position. The contact between wires 66 and 61 will remain closed and thereby hold the mercury tube 83 in dotted line position and also keep the bimetallic strip of unit 10 heated. The contacts between wires IOI and I02 will be kept closed and the circuit comprising members I01, I08, 21 and H0 will remain energized. The relay 85 which is in parallel with the thermal switch 10, will be energized through a circuit, comprising members LI, 33, 08, 85, I82, 68, 61, 60, 05, 53, 54, 52, 5!, 34 and L2 causing contact members Hit and I52 to be connected. This connection will permit the current to flow from lead L3, wire 35, switch 36, fuse 38, wire I50, cont-act I5I, switch arm I52, wire I53, post I54, heating coil I50, rheostat I51, rheostat arm I58, post 150,. wire I60, wire H5, and to terminal 22 of lead L2. Upon the closing of the circuit, the coil I58 of the intermittent thermal switch I55 will be heated thereby deflecting a bi-metallic strip comprising members I55 and I05. The lower end of member I60 supports a mercury tube I01 having mercury I58 therein. When the bimetallic strip has been heated sufiiciently long, the lower end thereof will deflect the mercury tube I61 from bold line position to dotted line position thereby closing the circuit between wires I16 and I11. The time interval which is necessary to cause the tube I01 to tilt the necessary amount for locking the circuit can be adjusted by manipulation of the screw I04 and rheostat arm I58. In the present instance, let us assume that this switch can be heated suinciently to close the circuit between the wires I16 and I11 within two minutes, after the heating coil has been subjected to electrical current.

Intermittent stopping circuit Upon the closing of the circuit between wires I16 and I11 the current is allowed to flow from the wire I00 through wire I15, wire I15, mercury I68, wire I11, wire I18, wire I19, relay coil I80, to lead LI. This will energize the relay coil I88 which, when energized, causes the switch arm I04 to move out of engagement with contact I06 and also cause the switch arm 92 to move into contact with the terminal SI. When the switch arm I04 moves from the terminal or contact I06, the circuit in which the mercury tube 83 is disposed will be broken, and the magnetic switch which has been held closed through the medium of the starting circuit comprising members I00 and I 08 inclusive, already described, will be opened thus de-energizing the magnet coil 21. When relay coil I is energized the switch arm 92 is raised into contact with terminal 9I. It is'now seen that when themagnetic switch 28 is open, no current is available for. the conductor II5, therefore, the heating coil I56 of the thermal switch I55 will not re position within a-set time.

ceive current thereby causing themetallic strip I65 to cool and assume the normal bold line When this metallic strip 0001s to restore the mercury tube I61 to bold. line position to open the circuit between wires I15 and III, the coil relay I80 will again be de-energized thereby causing the switch arm I04 to move into contact with terminal I56 to again energize. the magnet switch relay 21 and start the motor in the same manner as previously described. If the pump picks up water on this operation, it will continue to run as previously described, until the cut out by the time interval switch Ia. Otherwise the operation will be repeated as just described, relative to the failure to pick up water, as it will be seen that so long as pump I4 fails to pick up water mercury tube 41 will remain in closed position, continuing to energize mercury switch unit I5 and relay coil 86. Relay coil 86 when energized interrupts the holding circuit to magnet 21, and when deenergized, it closes the holding circuit.

Relay coil 86 also operates thermal switch I55, but in normal operation the switch is not closed, unless the pump fails to pick up water for a set time. We can assume the switch is set for two minutes for purpose of description. Let us assume that switch I5 closes in one and one-half minutes. Upon the closing of the last-named circuit, the mercury tube 41 will be tilted to open position thereby de-energizing magnet 85 resulting in the cooling of thermal switch I55 before it has been heated long enough to be closed. Therefore, it is only when the pump I4 fails to pick up water that the mercury tube 41' remains closed as long as two minutes which time interval is necessary for the switch I55 to be closed so as to operate the definite time switch 5 la.

Definite time switch circuit It will be noted by referring to relay coil IBil in Figure 2 that while this relay was energized and the switch arm 92 raised into contact with terminal 9| and that the current was caused to flow from wire I18, through wire 93, contact arm 92, terminal 9|, wire 90, motor 50 of time switch 5Ia, wire 89, and back to wire 5| thus completing the circuit, causing the motor 50 to operate during the period that the relay coil I80 was energized and during each succeeding operation of said relay until after a predetermined number of operations. After a predetermined number of failures to pick up water, the low side 56a of cam 56 will move out from beneath roller 55 thereby causing the roller to be on the high. side of cam. This will break the circuit between cotacts 53 and 54 thereby preventing further automatic operation of the system until conditions causing the trouble have been corrected. At this time the automatic control can be cut back in by manual reset of the definite time switch 5Ia. In addition to the above-mentioned operation, it will be seen that all three phases of the motor circuit are required to complete any step of the automatic controling device, thereby rendering complete single phase protection for three phase motors.

Signal circuit In order to provide means for indicating when the water is low in the tank after the pump has been finally cut off, a suitable pilot light and signal circuit is provided. The pilot light is indicated by reference character B and is installed between wires 2M and 202, said wires having their other ends connected to wire at and post a, respectively. The pilot light normally burns, but is cut off when the final cut-out is actuated to open contact between contacts 53 land 54.

In the drawings and specification there has been set forth a preferred embodiment of the invention and although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the following claims.

I claim:

1. Apparatus for maintaining a liquid level in a tank between a predetermined low level and a predetermined high level, comprising a pump and a pipe line between the pump and the tank, and electric motor for driving the pump, means operable by a predetermined low pressure for starting the motor, means rendered active by the starting of the motor for maintaining the motor energized for a predetermined time after the starting thereof, means for stopping said motor for a predetermined time interval upon the failure of the pump to pick up water, and means for again starting and maintaining the motor and pump in operation for a second predetermined interval.

2. In a water supply system having a tank, an electric motor, a pump driven by the motor, a pipe leading from the pump to said tank, an electric circuit to said motor, means'operable by the static pressure in the pipe line for closing the circuit to the motor, means independent of the pressure in said pipe for holding said circuit closed for a predetermined time after the starting thereof, means for opening said circuit for a predetermined time interval upon the failure of the pump to pick up water, means for again closing said circuit for a second predetermined interval to maintain the motor and pump in operation, and, means for successively repeating the opening and closing of said circuit for a predetermined number of times upon the failure of the pump to pick up water. r

3. In a water system having a tank, a pip line leading from the tank, a pump connected to the other end of said pipe line, an electric motor for driving said pump, an electrical circuit connected to said motor, a normally open switch in said circuit, means operable by a predetermined low pressure in said pipe line for closing said switch and starting said motor, means controlled by the starting of the motor and operable for a predetermined time after the motor has been started for maintaining said switch in closed position, means for opening said circuit for a predetermined time interval upon the failure of the pump to pick up water, means for again closing said circuit for a second predetermined interval to maintain the motor and pump in operation, and means for successively repeating the opening and closing of said circuuit for a predetermined number of times upon the failure of the pump to pick up water.

4. In a water system having a liquid pump and a tank disposed at a higher level thanthe pump and a pipe line connecting the pump and the tank, pressure operated means in said line disposed near the pump, a motor for driving the pump, means controlled by a predetermined low pressure in said line for starting said motor, means formaintaining said motor in operation for a predetermined time interval, means for stopping said motor for a predetermined time interval upon the failure of the pump to pick up liquid, means for again starting and maintaining the motor and pump in operation for a predetermined interval, and means for successively repeating said starting and stopping of said motor and pump for a predetermined number of times upon the failure of the pump to pick up liquid.

5. Apparatus for maintaining a supplyof water in a tank and the like between a predetermined low level and a predetermined high level, which comprises a pump having an intake pipe and a discharge pipe, said discharge pipe having its other end connected to the lower portion of said tank, an electric motor for driving said pump, a pressure operated switch connected to said discharge pipe and adapted to be closed upon the pressure in the discharge pipe reaching a predetermined low point and to be opened, when a predetermined high pressure is reached, said switch being disposed in close proximity to the pump, an electrical circuit connected to the motor for driving the same, a magnetic switch in said electrical circuit, a control circuit, a relay in said control circuit for operating said magnetic switch, a holding circuit for said relay and being operated from said control circuit, a time switch in the holding circuit, means operable by said pressure operated switch for closing said relay switch to cause the holding circuit to be energized, and a time controlled element in said holding circuit for holding said time switch closed to hold said magnetic switch closed for a predetermined time after the control circuit is broken by the increased pressure upon said pressure operated switch resulting from pump- 6. Apparatus for maintaining a supply of water in a tank and the like between a predetermined low level and a predetermined high level, which comprises a pump having an intake pipe and a discharge pipe, said discharge pipe having its other end connected to the lower portion of said tank, an electric motor for driving said pump, a pressure operated switch connected to said discharge pipe and adapted to be closed upon the pressure in the discharge pipe reaching a predetermined low point and to be opened when a predetermined high pressure is reached, said switch being disposed in close proximity to the pump, anelectrical circuit connected to the motor for driving the same, a magnetic switch in said electrical circuit, a control circuit, a relay in said control circuit for operating said magnetic switch, a holding circuit for said relay and being operated from said control circuit, a time switch in the holding circuit, means operable by said pressure operated switch for closing said relay switch to cause the holding circuit to be energized, a time controlled element in said holding circuit for holding said time switch closed to hold said magnetic switch closed for a predetermined time after the control circuit is broken by the increased pressure upon said pressure operated switch resulting from pumping, a second normally closed time switch in said control circuit, a second time controlled element for opening said second time switch to stop said motor, and means for operating said second element for a predetermined time interval upon the failure of the pump to create an increased pressure upon the pressure operated switch.

'7. Apparatus for maintaining a supply of water in a tank and the like between a predetermined low level and a predetermined high level, which comprises a pump having an intake pipe and a discharge pipe, said discharge pipe having its other end connected to the lower portion of said tank, an electric motor for driving said pump, a pressure operated switch connected to said discharge pipe and adapted to be closed upon the pressure in thedischarge pipe reaching a predetermined low point and to be opened when a predetermined high pressure is reached, said switch being disposed in close proximity to the pump, an electrical circuit connected to the motor for driving the same, a magnetic switch in said electrical circuit, a control circuit, a relay in said control circuit for operating said magnetic switch, a holding circuit for said relay, and being operated from said control circuit, a time witch in the holding circuit, means operable by said pressure operated switch for closing said relay switch to cause the holding circuit to be energized, a time controlled element in said holding circuit for holding said time switch closed to hold said magnetic switch closed for a predeter mined time after the control circuit is broken by the increased pressure upon said pressure operated switch resulting from pumping, and means for alternately starting and stopping said pump for predetermined intervals of time upon the failure of the pump to create an increased pressure upon the pressure operated switch.

8. Apparatus for maintaining a, supply of water in a tank and the like between a predetermined low level and a predetermined high level, which comprises a pump having an intake pipe and a discharge pipe, said discharge pipe having its other end connected to the lower portion of said tank, an electric motor for driving said pump, a pressure operated switch connected to said discharge pipe and adapted to be closed upon the pressure in the discharge pipe reaching a predetermined low point and to be opened when a predetermined high pressure is reached, said switch being disposed in close proximity to the pump, an electrical circuit connected to the motor for driving the same, a magnetic switch in said electrical circuit, a control circuit, a relay in said control circuit for operating said magnetic switch, a holding circuit for said relay and being operated from said control circuit, a time switch in the holding circuit, means operated by said pressure operated switch for closing said relay switch, to cause the holding circuit to be energized, a time controlled element in said holding circuit for holding said time switch after the control circuit is broken by the increased pressure upon said pressure operated switch resulting from pumping, means for alternately starting and stopping said pump for predetermined intervals of time upon the failure of the pump to create an increased pressure upon the pressure operated switch, a second normally closed time switch in said control circuit, a second time controlled element for opening said second time switch to stop said motor, and means for operating said second element for a predetermined time interval upon the failure of the pump to create an increased pressure upon the pressure operated switch.

MARION A. O'I'IERBOURG. 

